CMC Contact Terminal Material for Moisture Resistance and Lower Weight
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Solution Overview
Problem
Brass used in electrical contact terminals is vulnerable to moisture, experiences secular changes in physical properties, has high specific gravity, low electrical conductivity, and high energy loss, making it inefficient and difficult to handle.
Innovation Solution
A copper-mild steel-copper (CMC) metal material is developed, comprising a mild steel layer with pure copper layers bonded on both surfaces, offering improved electrical conductivity and resistance to moisture while reducing weight through a specific weight ratio of copper to mild steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brass is used for electrical contact terminals, then it is easy to cast and has good processibility, but it is vulnerable to moisture and has high possibility of natural cracks
Solution Approach 1:
The invention uses a composite structure consisting of a mild steel core layer and copper cladding layers. The mild steel core provides mechanical strength and resistance to moisture and cracking, while the copper cladding layers provide electrical conductivity and resistance to corrosion. This composite structure resolves the contradiction by combining materials with complementary properties rather than using a single brass material that cannot simultaneously satisfy both manufacturing ease and reliability requirements.
2Strength
If brass is used for electrical contact terminals, then it has good mechanical properties, but the electrical conductivity is as low as 25.0% IACS causing large energy loss
Solution Approach 1:
The invention employs a composite structure with a mild steel core layer providing mechanical strength and copper cladding layers providing high electrical conductivity. The copper layers have significantly higher electrical conductivity than brass, reducing energy loss while the mild steel core maintains the required mechanical properties. This resolves the contradiction by separating the functions of strength and electrical conductivity into different materials within the same component.
3Reliability
If brass is used for electrical contact terminals, then it has adequate performance, but it has high specific gravity making weight reduction difficult
Solution Approach 1:
The invention uses a composite structure where the mild steel core layer has lower specific gravity than brass, and the copper cladding layers are thin compared to the overall structure. The mild steel provides sufficient mechanical strength with lower density than brass, and the copper layers are minimized to only the thickness required for electrical conductivity. This composite approach achieves weight reduction while maintaining adequate performance.
4Adaptability or versatility
If brass is used for electrical contact terminals, then it has been widely used, but physical properties deteriorate with passage of time due to secular change
Solution Approach 1:
The invention uses a composite structure with a mild steel core layer and copper cladding layers bonded together. The mild steel core layer is resistant to secular changes and maintains stable physical properties over time, while the copper cladding layers provide electrical conductivity. The integral bonding between layers prevents delamination and maintains structural integrity. This composite structure resolves the contradiction by using materials with superior long-term stability while maintaining electrical functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The CMC structure provides superior electrical conductivity, resistance to secular changes, and reduced weight, enhancing energy efficiency and handling ease compared to brass, with electrical conductivity exceeding 28% IACS and specific gravity 95% or less than brass.
Implementation Method 1
the resistance of the mild steel layer is relatively greater than those of the first pure copper layer and the second pure copper layer, so that the specific gravity of current flowing through the first pure copper layer and the second pure copper layer is increased
Implementation Method 2
a first pure copper layer laminated and integrally bonded on a first surface of the mild steel layer thereto; and a second pure copper layer laminated and integrally bonded on a second surface of the mild steel layer
Data Source
Figure 1
AI summary
The present invention relates to a copper-mild steel-copper (CMC) metal material for an electrical contact terminal for replacing brass capable of obtaining an electrical contact terminal having electrical conductivity superior to that of brass, and strong resistance to moisture and secular change while implementing the reduction in weight by presenting a CMC structure instead of brass as a metal material for the electrical contact terminal to lower a ratio of copper.